Conductor of flexible material, component comprising such flexible conductor, and method of manufacturing such conductor

ABSTRACT

A conductor of flexible material on which electronic or electric components are arranged, is embedded at least partially in at least one shape-stable component. The conductor is manufactured by mounting the electric or electronic components on the flexible conductor, placing and positionally securing the conductor provided with the electric or electronic components into an injection mold, and embedding the conductor least partially in plastic material.

[0001] The invention relates to a conductor of flexible materialaccording to the preamble of claim 1, a modular component according tothe preamble of claim 9, as well as a method for manufacturing such aconductor according to the preamble of claim 25.

[0002] It is known, for example, in connection with lamp units for motorvehicles to arrange within the lamp housing a reflector which reflectsthe light emitted by the LEDs to the exterior. The LEDs are mounted on aflexible conductor foil. Mounting of the flexible conductor with theLEDs is difficult because the LEDs must be positioned in a precisemounting position within the lamp unit. This is difficult because of theflexibility of the conductor.

[0003] It is an object of the invention to configure the conductor ofthe aforementioned kind, the modular component of the aforementionedkind, and the method of the aforementioned kind such that the flexibleconductor can be mounted in a simple way in a desired mounting position.

[0004] This object is solved according to the invention for a conductorof the aforementioned kind by the characterizing features of claim 1,and, according to the invention, in regard to the component of theaforementioned kind by the characterizing features of claim 9, and,according to the invention, for the method of the aforementioned kindwith the characterizing features of claim 25.

[0005] The flexible conductor according to the invention is at leastpartially embedded within the shape-stable modular component. By meansof this shape-stable modular component, the conductor acquires its shapestability so that it can be mounted without problems in a precisemounting position. Moreover, the conductor is protected in theshape-stable modular component against damage.

[0006] In the modular component according to the invention, the flexibleconductor is embedded at least partially in the plastic layer.Accordingly, when mounting the modular component, the conductor nolonger must be mounted separately but forms together with theshape-stable plastic layer a modular component which can be mountedsimply.

[0007] According to the method of the invention, the conductor isprovided first with electronic and/or electric component andsubsequently inserted into the injection mold and positionally secured.Subsequently, the conductor is at least partially embedded in theplastic material. After hardening of the plastic material, the partiallyembedded conductor can be removed from the injection mold.

[0008] Further features of the invention result from the additionalclaims, the description, and the drawings.

[0009] The invention will be explained in more detail with the aid ofthe embodiment illustrated in the drawings. It is shown in:

[0010]FIG. 1 in a sectional view a part of a lamp unit with a conductoraccording to the invention;

[0011]FIG. 2 in a perspective illustration a reflector of the lamp unitaccording to FIG. 1 provided with the conductor according to theinvention;

[0012]FIG. 3 in a magnified illustration in section a portion of theconductor according to the invention;

[0013]FIG. 4 in section and in a simplified illustration an injectionmold for manufacturing the conductor according to the invention;

[0014]FIGS. 5 and 6 a further embodiment, respectively, of the componentaccording to the invention in an illustration corresponding to FIG. 3.

[0015]FIG. 1 shows a lamp unit which is a taillight of a motor vehiclein this embodiment. The lamp unit has a housing 1 in which a carrier 2is arranged. It is comprised preferably of plastic material but can alsobe made of other suitable material. The carrier 2 and a reflector 3 forma unitary part. The reflector reflects the rays emitted by theillumination means 4 to the lens 5 through which the light reaches theexterior. The configuration of such a taillight of motor vehicles isknown and is therefore not described in more detail. The lens 5 can beprovided at its inner side with illumination optics 6 which will beexplained by means of the embodiments according to FIGS. 5 and 6.

[0016] The reflector 3 has openings 7 in which the illumination means 4are positioned. As shown in FIG. 2, the reflector 3 has reflectorsurfaces 8 for each one of the illumination means 4, respectively. Theillumination means 4 are advantageously LEDs mounted on a conductor 9.It is also possible to employ SMDs as illumination means 4. As shown inFIG. 2, the illumination means 4 in this embodiment are arranged in thearea of the reflector surfaces in pairs. Depending on the configurationof the reflector 3, several such illumination means 4 can be correlatedwith the corresponding reflector surface 8. Of course, it is alsopossible to provide for each reflector surface 8 only a singleillumination means 4. In the embodiment, there are three additionalillumination means 4 provided on the side; they are positioned at aspacing from one another. Advantageously, they are also LEDs and do notradiate through the lens 4 but transversely thereto.

[0017] The conductor 9 is a flexible conductor foil via which thecurrent supply to the illumination means 4 is realized as is known inthe art. Since the conductor 9 is flexible, it can be matched to anyshape of the carrier 2 and/or of the reflector 3.

[0018] The carrier 2 and the reflector 3 enclose the conductor 9. Whenmanufacturing the carrier 2 and the reflector 3, the conductor 9 isembedded by the material of these two parts 2, 3. In this way, theconductor 9 is properly secured and protected. FIG. 4 showsschematically a portion of an injection mold. It has to mold parts 10,11, wherein mold part 10 is stationary and mold part 11 is movable. Bothmold parts 10, 11 have at least one securing plunger 12, 13 arranged soas to be movable relative to one another within the shaped parts 10, 11.Between them, the flexible conductor 9 is clamped during the injectionmolding process. The two securing plungers 12, 13 are adjustable in thedirection of the double arrow 14, 15 illustrated in FIG. 4. Bothsecuring plungers 12, 13 are configured such that they have at least onehollow space 16, 17. The two hollow spaces 16, 17 are positionedopposite one another and form a common hollow space divided by theconductor 9. The hollow space is configured such that the illuminationmeans 4 mounted on the conductor 9 can be received therein during theinjection molding process. The two holding plungers 12, 13 clamp theconductor 9 in the area adjacent to the illumination means 4 such thatthe plastic material introduced into the injection mold cannot penetrateinto the hollow space 16, 17.

[0019] Depending on the number of illumination means 4 which are mountedon the conductor 9, a corresponding number of securing plungers withcorresponding hollow spaces are provided in the injection mold.

[0020] A vacuum channel 18 can open into the hollow space 16 of onesecuring plunger 12 via which a vacuum can be created in the hollowspace during the injection molding process.

[0021] The injection mold can be provided additionally with at least oneloading plunger 19.

[0022] As is known in the art, the plastic material for the carrier 2and the reflector 3 is injected into the injection mold. The conductor 9which is clamped in the hollow space 20 between the securing plungers12,13 is embedded in this plastic material. The illumination means 4provided on the conductor 9 are protected during this injection moldingprocess within the space 16, 17 of the securing plungers 12, 13. Thesecuring plungers 12, 13 are configured such that they clamp theconductor 9 only in direct vicinity of the illumination means 4 so thatin other areas the conductor 9 can be embedded in the plastic materialfor the carrier 2 and the reflector 3. As a result of the clampingaction of the conductor 9 by means of the securing plungers 12, 13, itis ensured that the illumination means 4 are in their exact mountingposition on the carrier 2 and the reflector 3. The flexible foil-likeconductor 9 itself must not have a precise mounting position because itis embedded by the plastic material of the carrier 2 and of thereflector 3 and, in this way, is positionally 20 secured. After theinjection molding process, the injection mold is opened so that themodular unit comprised of the carrier 2, the reflector 3, and theembedded conductor 9 can be removed and mounted in the housing 1. Inthis way, the manufacture and assembly of the lamp unit is simple andinexpensive.

[0023] The lamp unit can be, for example, a turn signal, a taillight, aheadlight, or generally a signal light of a motor vehicle. However, theembedded conductor can also be used for interior and/or instrumentationillumination of motor vehicles, for example, as a dashboard light,cockpit light, a door handle light and the like.

[0024] In addition to the illumination means, sensors or otherelectronic and/or electric components can be mounted on the conductor 9embedded in the plastic material. In addition to its use in motorvehicles, the embedded conductor 9 can be used also in cameras, acousticsignaling devices and the like.

[0025]FIG. 5 shows a lamp unit in which the conductor 9, in accordancewith the afore described embodiment, is arranged between a carrier 2 aand a reflector 3 a. The conductor 9 a supports also LEDs 4 a, which arelocated in openings 7 a of the reflector 3 a. This lamp unit differsfrom that according to FIGS. 1 through 4 only in that instead of thelens 5 a light guide 21 is provided which is manufactured, as is knownin the art, of a light-conducting plastic material. The light guide 21has optics 22 which are formed as unitary truncated cone-shapedprojections on the inner side 23 of the light guide 21. Each LED 4 a isprovided with optics 22. By means of these optics 22 integrated into theconductor 21, the conventional lens 5 can be eliminated. Lamps with sucha configuration are extremely flat and require only a minimal mountingspace on the vehicle. Advantageously, it is possible in this way toemploy a closed sheet metal skin on the vehicle. Moreover, this lampunit is comprised of only a few individual parts so that it can beinexpensively manufactured and mounted. Moreover, it is also possible toemploy vapor-deposit parts. Also, filters for generating a desired colorare not required in the lens because the light guide 21 can be havedifferent colors. In this embodiment, it is also possible to provide,instead of the reflector 3 a, only a single plastic layer which isprovided only at the side facing the light guide 21 with anelectroluminescent foil (not illustrated) or a reflector band.Preferably, the foil or the band is inserted into the outer side of theplastic layer 2 a.

[0026] As shown in FIG. 6, the end faces of the optics 22 facing theLEDS 4 a can be profiled and, accordingly, can serve as reflectors.

[0027] Since the conductors 9, 9 a are embedded in plastic material, anoptimal heat distribution and heat dissipation result. Additionalmeasures for heat distribution or heat dissipation are therefore notrequired.

[0028] The plastic material for the carrier 2 or 2 a and/or thereflector 3 can be thermoplastic materials, such as polycarbonate,acrylonitrile butadiene styrene copolymer (ABS), polybutyleneterephthalate (PBT), polyamide and similar materials. Thermoplasticmaterials have a relatively low melting point so that, when injectionmolding the carrier 2, 2 a and the reflector 3, 3 a there is no risk ofdamaging the electric and/or electronic components 4, 4 a arranged onthe conductor 9, 9 a.

[0029] For improving the heat dissipation, additives can be added to theplastic material, for example, mineral materials, glass, powder, fibers,ceramic materials and similar materials. These additives can be presentin an amount of up to approximately 60 % by weight.

1. A conductor of flexible material on which electronic and/or electriccomponents are arranged, characterized in that the conductor (9, 9 a) isembedded at least partially in at least one shape-stable component (2, 2a, 3, 3 a).
 2. The conductor according to claim 1, characterized in thatthe shape-stable component (2, 2 a, 3, 3 a) is comprised of plasticmaterial.
 3. The conductor according to claim 2, characterized in thatthe plastic material is at least one thermoplastic material.
 4. Theconductor according to claim 2, characterized in that the plasticmaterial contains additives.
 5. The conductor according to claim 4,characterized in that the additives are present in the plastic materialup to approximately 60% by weight.
 6. The conductor according to claim4, characterized in that the additives are comprised of heat-dissipatingmaterial such as mineral substances, fibers, ceramics and like.
 7. Theconductor according to claim 1, characterized in that the shape-stablecomponent (2, 2 a, 3, 3 a) is comprised of two functional parts.
 8. Theconductor according to claim 1, characterized in that the shape-stablecomponent (2, 2 a, 3, 3 a) is recessed in the area of the electronicand/or electric components (4, 4 a).
 9. A modular component, inparticular for motor vehicles, comprising at least one flexibleconductor on which at least one electric and/or electronic component isarranged, especially according to claim 1, characterized in that theflexible conductor (9, 9 a) is at least partially embedded in a plasticlayer (3, 3 a).
 10. The modular component according to claim 9,characterized in that the plastic layer (3, 3 a) is arranged on acarrier (2, 2 a).
 11. The modular component according to claim 9,characterized in that the carrier (2, 2 a) and the plastic layer (3, 3a) form a single unitary part.
 12. The modular component according toclaim 9, characterized in that the illuminating means (4, 4 a) projectsthrough an opening (7, 7 a) of the plastic layer (3, 3 a).
 13. Themodular component according to claim 9, characterized in that theplastic layer (3, 3 a) is a reflector.
 14. The modular componentaccording to claim 9, characterized in that the illuminating means (4, 4a) is an LED or an SMD.
 15. The modular component according to claim 9,characterized in that a light guide (21) is arranged in front of theplastic layer (3 a) and/or in front of the illuminating means (4 a). 16.The modular component according to claim 15, characterized in that thelight guide (21) comprises at least one illumination optics (22)correlated with the illumination means (4 a).
 17. The modular componentaccording to claim 16, characterized in that the illumination optics(22) is formed as a part of the light guide (21).
 18. The modularcomponent according to claim 15, characterized in that the light guide(21) is multi-colored.
 19. The modular component according to claim 16,characterized in that the illumination optics (22) is formed by aprojection projecting past the inner side (23) of the light guide (21).20. The modular component according to claim 16, characterized in thateach illumination means (4 a) has correlated therewith at least oneillumination optics (22).
 21. The modular component according to claim16, characterized in that the illumination optics (22) has at least onereflector surface (24).
 22. The modular component according to claim 21,characterized in that the reflector surface (24) is formed by atooth-like profiling of the end faces of the illumination optics (22).23. The modular component according to claim 9, characterized in thatthe plastic layer (3 a) at its side facing the light guide (21) has atleast one reflector part.
 24. The modular component according to claim9, characterized in that the modular component is used for a light unitof a motor vehicle.
 25. A method for manufacturing the conductoraccording to claim 1, characterized in that the electronic and/orelectric component (4, 4 a) is mounted on a flexible conductor (9, 9 a),that the conductor (9, 9 a) provided with the components (4, 4 a) isplaced into an injection mold and positionally secured, and that theconductor (9, 9 a) is at least partially embedded in plastic material.26. The method according to claim 25, characterized in that theconductor (9, 9 a) is clamped between at least two securing plungers(12, 13) of the injection mold.
 27. The method according to claim 26,characterizing that at least one securing plunger (12, 13) has a hollowchamber (16, 16 a, 17) in which the electronic and/or the electriccomponent (4, 4 a) is seal-tightly positioned during the injectionprocess.
 28. The method according to claim 27, characterized in that thehollow chamber (16, 16 a, 17) is subjected to vacuum.
 29. The methodaccording to claim 27, characterized in that the securing plunger (12,13) clamps the conductor (9, 9 a) in an area of the electronic and/orelectric component (4, 4 a).